Method of making a puffed fabric



A. N. LOWENSTEIN 3,270,696

7 METHOD OF MAKING A PUFFED FABRIC Sept. 6, 1966 2 Sheets-Sheet 1 Filed Oct. 11, 196::

60 55 6 INVENTOR flLv/N N LOWENSTE/N mmmm Sept. 6, 1966 N. LOWENSTEIN 3,

METHOD OF MAKING A PUFFED FABRIC Filed Oct. 11, 1965 2 Sheets-Sheet 2 54 INVENTOR.

flLv/A/ LowEA/sTE/M United States Patent 3,270,696 METHOD OF MAKING A PUFFED FABRIC Alvin N. Lowenstein, Elizabeth, N.J., assignor to McGregor-Doniger Inc., New York, N.Y., a corporation of New York Filed Oct. 11, 1963, Ser. No. 315,579 2 Claims. (Cl. 112262) My invention relates to a puffed fabric and method of making the same, which fabric has a strikingly attractive appearance and which combines the properties of thermal insulation and stretchability in a unique manner.

There are a wide variety of fabrics known in the prior art. These fabrics are designed to have qualities which suit them for the purposes for which they are intended. Some fabrics of the prior art are quilted to provide good thermal insulation. One use of such a fabric is as a lining for an outer garment. While these quilted fabrics provide warmth, they are heavy and cumbersome. More over, they are relatively inextensible. Consequently, a garment embodying such a lining is not as comfortable as is desirable for use in a garment worn by a person engaged in relatively strenuousphysical activity.

I have invented a puffed fabric which over-comes the defects of fabrics pointed out hereinabove. It uniquely combines the properties of good thermal insulation with stretchability. It is light. It presents a highly attractive appearance.

One object of my invention is to provide a puffed fabric which combines the properties of good thermal insulation with stretchability.

Another object of my invention is to provide a light thermal insulating fabric.

A further object of my invention is to provide a fabric which has a strikingly attractive appearance.

Other and further objects of my invention will appear from the following description.

In general my invention contemplates the provision of a puffed fabric comprising a relaxed two-way stretch fabric quilted with a face fabric to form a plurality of deep puffs, the shape of which is determined by the orientation of the quilting stitches. If necessary or desirable, my fabric may incorporate a fibrous filler and a backing fabric.

In my method of producing the puffed quilted fabric, I quilt the stretchable fabric while stretched in both directions with an unstretched face fabric so that the face fabric forms the deep puffs when the stretchable fabric is released.

In the accompanying drawings which form part of the instant specification and which are to be read in conjunction therewith and in which like reference numerals are used to indicate like parts in the various views:

FIGURE 1 is a schematic view illustrating one form of apparatus on which I may practice my method of producing my puffed fabric.

FIGURE 2 is a plan view of the apparatus shown in FIGURE 1 taken along the line 2--2 of FIGURE 1.

FIGURE 3 is a fragmentary plan view illustrating one form of my puffed fabric in its stretched condition.

'FIGURE 4 is a sectional view of the form of my puffed fabric shown in FIGURE 3 taken along the line 44 of FIGURE 3.

FIGURE 5 is a fragmentary plan view of the form of my puffed fabric shown in FIGURE 3 in the relaxed state.

FIGURE 6 is a sectional view of the form of my puffed fabric shown in FIGURE 5 taken along the line 66 of FIGURE 5.

FIGURE 7 is a sectional view of the form of my puffed fabric shown in FIGURE 5 taken along the line 7-7 of FIGURE 5.

Referring now to FIGURES 1 and 2 of the drawings, one form of apparatus which I may employ to carry out my process for producing my puffed fabric includes a fabric includes a frame indicated generally by the reference character 10 and uprights 12 and 14. The uprights 12 and 14 carry brackets 16 and 18 which rotatably support a let-off roller 20 carrying a roll 22 of the two-way stretch fabric of my puffed fabric. In winding the twoway stretch fabric 24 on the roller 20, I stretch it to the desired degree in the direction of its length. That is, in winding the fabric 24 on the roll 20, I stretch the fabric longitudinally from about 30 percent to as much as percent. I

It will be appreciated that I may use any suitable twoway stretch fabric 24. For example, the fabric 24 may be formed from yarns spun from segmented polyurethane polymer fibers, which is manufactured by E. I. du Pont de Nemours & Company and sold under the registered trademark Lycra. This material has the highly desirable properties of high strength, uniformity, abrasion resist-ance, high modulus and flex life, as well as resistance to weathering. The fabric 24 may be formed on a warp knitting machine which draws threads of each yarn of the fabric into the adjacent yarn to provide a netlike structure. From its relaxed state, the fabric 24 may be stretched both longitudinally and transversely.

As is pointed out hereinabove, the fabric 24 is wound under tension onto the roller 20 to form the roll 22 of longitudinally stretched fabric 24. Preferably, I provide the roller 20 with a let-off mechanism (not shown) of any suiable type known to the art, which determines the rate at which the fabric is released.

Respective pairs of sprocket wheels 26 and 28 carry pitch chains 30 disposed in guides 32 and 34 which guide the chains along divergent paths over a portion of their length. The chains 30 carry a plurality of hooks 36 or the like adapted to engage the fabric 24 as it is released from the roll 22. Owing to the fact that the chains 30 travel along divergent paths over a portion of their lengths, the fabric 24, which has been prestretched longitudinally, is stretched transversely as it is carried along with the chains 30.

Uprights 12 and 14 support a plurality of let-off rollers 38, 40 and 42 which carry, respectively, a roll 44 of fabric 46 which is to form the face fabric of my puffed fabric, a roll 48 of a fibrous mat or bat 50 which may form a filler for my puffed fabric and a roll 52 of a backing 54 which I may employ on my puffed fabric.

It will readily be appreciated that the face fabric may be formed of any suitable material such, for example, as nylon, silk, cotton, rayon or any synthetic material or blends of any of these fibers. It may be plain but, preferably, it is patterned so as to enhance the appearance of the finished puffed fabric. The mat or bat 50 is made up of any suitable fibrous material such, for example, as polyacrylic resinous fiber, cotton, wool or any other fibrous bat-forming material. The backing 54 is preferably a light muslin or cheesecloth. It will be apparent from the description hereinafter that the essential elements of my puffed fabric are the stretchable net material 24 and the face fabric 46.

After the material 24 has been stretched transversely to the desired extent, which may be from about 30 percent to as much as 100 percent of its initial width, it passes over a table 58 disposed between two parallel extents of the chains 30 below a multiple head stitching mechanism 60 of any suitable type known to the art. Respective guide rollers 62, 64, and 66 guide the face fabric 46, the bat 50 and the backing 54 to the space between the mechanism 60 and the table 58. It will readily be apparent that the fabric 46 and the bat 50, as well as the backing 54 all have widths which are substantially equal to the width of the stretchable fabric 24 after it has been stretched longitudinally.

After having passed through the space between table 58 and the mechanism 60 the layers of fabricare received by a roll 68 provided with a suitable take-up mechanism 70 which drives the roll to draw the material through the apparatus.

Since the apparatus on which I practice my method does not per se form a part of my invention, I have not described it in detail. The sewing mechanism 60 may be of any suitable type known to the art adapted to be shogged to determine the orientation of the lines of quilting stitches applied to the superposed fabric layers as they pass through the machine.

Referring now to FIGURE 3 of the drawings, in one form of my puffed fabric indicated generally by the reference character 72, mechanism 60 may apply lines 74 of quilting stitches in a diamond pattern. Thus, in the stretched condition of the fabric 72, it comprises a decorative face fabric 46, the mat 50, the two-way stretched mesh 24 and the backing 54 all held together by quilting stitches 74. Now when the fabric is released to permit the mesh 24 to assume its original dimensions, the fabric 72 contracts to the condition illustrated in FIGURES 5 and 6 to form a plurality of deep puffs 76 of the face fabric 46 and other deep puffs 78 of the backing 54. These puffs 76 and 78 are formed as the contracting mesh material 24 gathers the face fabric 46 and the backing 54.

In the form of my fabric in which I employ the inner bat 50, it lends some body to the puffs 76 which are normally exposed to view in use of the fabric. The puffs 78 on the other hand may be flattened in use. It is to be appreciated that while I have shown a form of my fabric in which I employ a bat 50 as well as the backing 54, I may merely form myfabric by use of the two-way stretch mesh material 24 and the desired face fabric 46.

- In practice of my method of making my puffed fabric- 72, the mechanism 70 draws the backing 54, the longitudinally prest-retched mesh material 24, the bat 50 and the face fabric 46 in superposed relationship over the table 58 below the stitching mechanism 60. As the superposed materials approach the table 58, the mesh 24 is stretched transversely to the desired extent. As is pointed out hereinabove, both the longitudinal stretch and the transverse stretch of the material 24 may be from about 30 percent up to 100 percent of the original dimensions of the fabric 24;

As the superposed materials pass under the mechanism 60, the latter is actuated to produce the desired pattern of stitches. For example, the stitches may be applied in a diamond pattern to produce a diamond puffed fabric. Alternatively, zigzag lines of stitches may be applied to form a resultant shirred puffed fabric. It will be appreciated that suitable let-off mechanisms of any type known in the art may be employed to control the rate at which material is let off from the various rolls 22, 44, 48 and 52. It will also readily be understood that the lateral or transverse stretching operation can be accomplished by hand and the lines of stitching 74 can be aptive appearance. My puifed fabric 72 is adaptable to a very Wide variety of uses. One of the most significant uses for my fabric is in garments which are adapted to provide warmth and at the same time which permit the wearer freedom of movement. More specifically, my fabric provides a light, non-bulky, warm stretchable lining for clothing adapted for use by persons engaging in winter sports. While it is eminently suited for this use, it is of course adaptable to many other uses.

It will be seen that I have accomplished the objects of my invention. I have provided a puffed fabric having a strikingly attractive appearance and yet which is stretchable. One form of my fabric provides a good thermal insulation while at the same time being light, not bulky and stretchable. I have provided a method for making my fabric in a simple and expeditious manner.

It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of my claims. It is further obvious that various changes may be made in details within the scope of my claims without departing from-the spirit of my invention. It is, therefore, to be understood that my invention is not to be limited to the specific details shown and described.

Having thus described my invention, what I claim is:

1. A continuous method of making a puffed fabric in cluding the steps of feeding a two-way stretchable fabric through a stitching zone, stretching said fabric in the direction offeeding in the course of said feeding operation, concomitantly stretching said fabric in a direction trans verse to the direction of feeding in the course of said feeding operation as it passes through said zone, feeding a relatively inextensible'face fabric through said zone together with said stretchable fabric and securing said fabrics together in said zone with stitching extending both in the direction of feeding and transversely thereto.

2. A method as in claim 1 including the steps of as sembling a bat of fibrous material between said fabrics and feeding said bat through said zone with said fabrics.

References Cited by the Examiner UNITED STATES PATENTS Re. 24,007 5/ 1955 Foster 28-72 857,968 6/1907 Wertheim 112-414 1,606,899 11/ 1926 Rockwood 112-414 2,165,469 7/1939 Fellegi 112-414 2,401,830 6/1946 Kahil 112-262 X 2,564,959 8/1951 Corallo 112-414 2,977,664 4/1961 Grajeck 28-72 3,013,588 12/1961 Klingberg 139-410 3,195,489 7/ 1965 Estephanian 112-266 FOREIGN PATENTS 1,066,914 1/1954 France. 1,258,337 3/1961 France. 1,258,476 3/ 1961 France. I 485,803 11/ 1929 Germany.

FRANK J. COHEN, Primary Examiner.

JORDAN FRANKLIN, Examiner.

J. R. BOLER, Assistant Examiner. 

1. A CONTINUOUS METHOD OF MAKING A PUFFED FABRIC IN CLUDING THE STEPS OF FEEDING A TWO-WAY STRETCHABLE FABRIC THROUGH A STITCHING ZONE, STRETCHING SAID FABRIC IN THE DIRECTION OF FEEDING IN THE COURSE OF SAID FEEDING OPERATION, CONCOMITANTLY STRETCHING SAID FABRIC IN A DIRECTION TRANSVERSE TO THE DIRECTION OF FEEDING IN THE COURSE OF SAID FEEDING OPERATION AS IT PASSES THROUGH SAID ZONE, FEEDING A RELATIVELY INEXTENSIBLE FACE FABRIC THROUGH SAID ZONE TOGETHER WITH SAID STRETCHABLE FABRIC AND SECURING SAID FABRICS TOGETHER IN SAID ZONE WITH STITCHING EXTENDING BOTH IN THE DIRECTION OF FEEDING AND TRANSVERSELY THERETO. 